Improving Efficiency & Reliability

of

STEAM TURBINE
Through R & M

BY:
AMITABH SRIVASTAVA
SR.DGM, BHEL HARDWAR

IN THE PRESENT POWER SECTOR

SCENARIO

FOCUS IS ON

ENHANCING EFFICIENCY
RELIABILITY
STRICTER POLLUTION NORMS
COST REDUCTION

RESULTING TO ENHANCED EMPHASIS ON

=> REDUCTION IN GENERATION COST

HIGH EFFICIENCY OF TG CYCLE

LOWER EQUIPMENT COST
SHORTER GESTATION PERIOD
REDUCED MAINTENANCE TIME

=> INCREASED RELIABILITY

=> MINIMIZING ENVIRONMENTAL
HAZARDS

IMPROVEMENT IN STEAM TURBINE

PERFORMANCE

POSSIBLE BY
1. IMPROVED BLADE PROFILE
REDUCTION IN THE AERODYNAMIC
FLOW LOSSES e.g.
PROFILE LOSS
SECONDARY FLOW LOSS
TIP LEAKAGE LOSS
MORE UNIFORM FLOW DISTRIBUTION
CONTD..

IMPROVEMENT IN STEAM TURBINE

PERFORMANCE
POSSIBLE BY
2.
3.
4.
5.
6.

.contd...

OPTIMISED FLOWPATH
IMPROVEMENT IN SHAFT SEALING SYSTEM
REDUCTION IN PRESSURE DROPS
REDUCED FRICTION LOSSES
OPTIMISATION OF INLET & EXHAUST
SECTION
7. OPTIMISED EXHAUST LOSS

DEVELOPMENT OF PROFILES FOR

CYLINDRICAL TURBINE BLADES

T4 PROFILE HAS 1% LOWER

PROFILE LOSSES COMPARED
TO T2 PROFILE.

NEWLY DEVELOPED TX HAS

0.2% LOWER PROFILE LOSSES
COMPARED TO T4 PROFILE.

CONSIDERATIONS IN RETROFITTING &

UPGRADATION OF OLDER SETS
COST EFFECTIVENESS
MODIFICATIONS IN TURBINE INTERNALS
ONLY
INCREASE IN POWER OUTPUT WITH MINIMUM
CHANGES
OUTER CASING, PIPINGS, VALVES, PEDESTAL
FIXING ARRANGEMENT , STEAM PARAMETERS
& FOUNDATION DETAILS REMAIN UNALTERED
SHORTEST POSSIBLE OUTAGE TIME

RETROFITTING & UPGRADATION OF OLDER

SETS
PRE-REQUISITE

IDENTIFY THE UNIT

PRESENT LEVEL OF PERFORMANCE
RESIDUAL LIFE ASSESSMENT STUDY OF
CRITICAL COMPONENTS
ANALYSIS OF HISTORY & OPERATING
DETAILS

RETROFITTING & UPGRADATION OF OLDER

SETS

MAJOR MODIFICATIONS IN
GUIDE & MOVING BLADE
(LATEST STATE OF ART
PROFILE)

3 DS BLADE

TWISTED PROFILE

(HPT/IPT)

BLADE (HP/IPT)

BANANA TYPE
BLADE (LPT)

STEAM FLOWPATH
ROTORS & INNER CASINGS
OF TURBINE
SHAFT SEALINGS
[ADVANTAGE IN HEATRATE /
OUTPUT CAN BE WORKED
OUT ON CASE TO CASE
BASIS]

Retrofitting of HP Turbine
with
STATE OF ART REACTION
BLADING

210 MW STEAM TURBINE

(IMPULSE DESIGN SET-LMW)

HP TURBINE

210 MW STEAM TURBINE

(IMPULSE DESIGN SET)

HP TURBINE

EXISTING 210 MW HP TURBINE

WITH IMPULSE BLADING

PROPOSED NEW DESIGN WITH

LATEST STATE OF ART BLADING

HP TURBINE
EXISTING

NEW

IMPULSE BLADING
( PRESSURE DROP
ONLY IN STATIONARY
BLADES)
EFFICIENCY : 83.6 %
(FOR NEW MACHINE)
EFFICIENCY FOR
EXISTING CONDITION :
~ 80%

REACTION BLADING
( PRESSURE DROP IN
STATIONARY AS WELL
AS MOVING BLADES

EFFICIENCY : 86.5 %

ACTIVITIES INVOLVED

REMOVAL OF EXISTING HP ROTOR,

LINERS AND DIAPHRAGMS
INSTALLATION OF NEW LINERS FITTED
WITH STATIONARY BLADES AND NEW HP
ROTOR
FITTING DIMENSIONS ARE TO BE
MEASURED
DURING
PREVIOUS
OVERHAUL AND LINERS ARE MACHINED
ACCORDINGLY.
REMOVED HP ROTOR AND DIAPHRAGMS
CAN BE USED AS SPARE FOR OTHER
SETS

ACTIVITIES INVOLVED

THE RETROFIT CAN BE DONE WITHIN

NORMAL OVERHAUL PERIOD.

PAY BACK PERIOD IS LESS THAN 3

YEARS

A.
A. Reference
Reference data
data for
for ORIGINAL
ORIGINAL brand
brand
new
new turbine
turbine
Reference
Reference Heat
Heat Balance
Balance Diagram
Diagram
TCD
TCD -- 210
210 -- 33
33 -- 2,
2, Regime
Regime No.
No. 11
Rated
Rated parameters
parameters
Main
662
Main steam
steam Flow
Flow
662 T/h
T/h
Main
130
Main Steam
Steam Pressure
Pressure
130 ata
ata
Main
Main Steam
Steam Temperature
Temperature 535
535 Deg
Deg C
C
Hot
Hot reheat
reheat Temperature
Temperature 535
535 Deg
Deg C
C
Condenser
0.1042
Condenser Vacuum
Vacuum
0.1042 ata
ata
TG
2062
TG Heatrate
Heatrate
2062 kCal/kWh
kCal/kWh

B.
B. Expected
Expected present
present performance
performance level
level
(210
(210 MW
MW Original
Original rating)
rating)
Considering
Considering deterioration
deterioration due
due to
to ageing
ageing as
as per
per

ASME-PTC-6Report
ASME-PTC-6Report 1985
1985

Expected
Expected Power
Power output
output
with
with 662
662 T/h
T/h main
main steam
steam flow
flow
and
and rated
rated parameters
parameters

202.4
202.4 MW
MW

Expected
Expected TG
TG Heatrate
Heatrate
with
with 662
662 T/h
T/h main
main steam
steam flow
flow
and
and rated
rated parameters
parameters 2164
2164 kCal/kWh
kCal/kWh

EXPECTED PERFORMANCE IMPROVEMENT

IN THE EXISTING IMPULSE DESIGN SET DUE
TO HP TURBINE REFURBISHMENT
INCREASE

IN POWER OUTPUT : 8.6

MW
IMPROVEMENT IN HEATRATE : 4%
(FROM EXISTING PERFORMANCE LEVEL OF
THE SET WITH RATED STEAM PARAMETERS &
THROTTLE STEAM FLOW)

EXPECTED PERFORMANCE IMPROVEMENT IN THE

EXISTING IMPULSE DESIGN SET DUE TO HP TURBINE
REFURBISHMENT

BRAND NEW
SET

OUTPUT
(MW)
HEAT
RATE
(KCAL/
KWh)

EXPECTED
UPGRADED
PRESENT
HPT
DETERIORATE
D CONDITION

210 202.4 (3.6%

DECREASE)
2062 2164 (4.9%
INCREASE)

211 (4.2%
INCREAS
E)
2077
(4.02%
IMPROVE
MENT)

COMPARISON
GAIN WITH UPRATED HPT:
ADDITIONAL GEN. OF MU = MW X1000 X HRS.X PLF
= 8.6 X 1000 X 8000 X 0.80 = 55.04 MU
ADDITIONAL GEN. OF REVENUE @ RS 2/= PER UNIT
= 55.04 X 2 = RS 11 CR

200/210 MW IMPULSE DESIGN

SET
(LMW)

EXISTING

AFTER RETROFIT

WORK INVOLVED IN RETROFIT OF LP

TURBINE
WORK TO BE DONE AT SITE:
CUTTING OF DEFLECTORS / RIBS &
BLANKING THE SPACE IN LP CASING TO
FACILITATE REMOVAL OF BAUMEN STAGE.
MODIFICATION OF STRUCTURE AT THE
EXHAUST END OF LPC TO FACILITATE
INSTALLATION OF DIFFUSOR.
CONTD.

WORK INVOLVED IN RETROFIT OF LP

TURBINE
WORK TO BE DONE AT SITE:
MODIFICATION OF STRUCTURE
AT THE STEAM INLET END OF LPC
TO FACILITATE INSTALLATION
OF 1ST STAGE OF GUIDE BLADES.

A.
A. Reference
Reference data
data for
for ORIGINAL
ORIGINAL brand
brand
new
new turbine
turbine
Reference
Reference Heat
Heat Balance
Balance Diagram
Diagram
TCD
TCD -- 210
210 -- 33
33 -- 2,
2, Regime
Regime No.
No. 11
Rated
Rated parameters
parameters
Main
662
Main steam
steam Flow
Flow
662 T/h
T/h
Main
130
Main Steam
Steam Pressure
Pressure
130 ata
ata
Main
Main Steam
Steam Temperature
Temperature 535
535 Deg
Deg C
C
Hot
Hot reheat
reheat Temperature
Temperature 535
535 Deg
Deg C
C
Condenser
0.1042
Condenser Vacuum
Vacuum
0.1042 ata
ata
TG
2062
TG Heatrate
Heatrate
2062 kCal/kWh
kCal/kWh

B.
B. Expected
Expected present
present performance
performance level
level
(210
(210 MW
MW Original
Original rating)
rating)
Considering
Considering deterioration
deterioration due
due to
to ageing
ageing as
as per
per

ASME-PTC-6Report
ASME-PTC-6Report 1985
1985

Expected
Expected Power
Power output
output
with
with 662
662 T/h
T/h main
main steam
steam flow
flow
and
and rated
rated parameters
parameters

202.4
202.4 MW
MW

Expected
Expected TG
TG Heatrate
Heatrate
with
with 662
662 T/h
T/h main
main steam
steam flow
flow
and
and rated
rated parameters
parameters 2164
2164 kCal/kWh
kCal/kWh

EXPECTED PERFORMANCE
IMPROVEMENT IN THE EXISTING SET DUE
TO LP TURBINE REFURBISHMENT
INCREASE

IN POWER OUTPUT : 10.1 MW

IMPROVEMENT IN HEATRATE : 102
KCAL / KWH
(FROM EXISTING PERFORMANCE LEVEL OF THE
SET WITH RATED STEAM PARAMETERS &
THROTTLE STEAM FLOW)

COMPARISON

BRAND
NEW ST

OUTPUT
(MW)
HEAT RATE
(KCAL /
KWH)
ADDITIOAL
GEN (MU)

EXPECTED
PRESENT
DETERIORA
TED
CONDITION

UPGRADED
LPT

210

202.4

212.5

2062

2164

2066

NA

NA

64.64

COMPARISON
GAIN WITH UPRATED LPT:
ADDITIONAL GEN. OF MU = MW X1000 X HRS.X PLF
= 10.1 X 1000 X 8000 X 0.80 = 64.64 MU
ADDITIONAL GEN. OF REVENUE @ RS 2/= PER UNIT
= 64.64 X 2 = RS 12.93 CR

COMPARISON

BRAND
NEW ST

OUTPUT
(MW)
HEAT RATE
(KCAL /
KWH)
ADDITIOAL
GEN (MU)

EXPECTED UPGRADED UPGRADED UPGRADED

PRESENT
HPT
LPT
HPT & LPT
DETERIORA
TED
CONDITION

210

202.4

211

212.5

214

2062

2164

2077

2066

2047

55.04

64.64

74.24

NA

NA

COMPARISON
GAIN WITH UPRATED HPT & LPT:
ADDITIONAL GEN. OF MU = MW X1000 X HRS.X PLF
= 11.6 X 1000 X 8000 X 0.80 = 74.74 MU
ADDITIONAL GEN. OF REVENUE @ RS 2/= PER UNIT
= 74.74 X 2 = RS 14.848 CR

TECHNICAL PROPOSAL
FOR R & M OF 210 MW
STEAM TURBINES (KWU
DESIGN) OF TUTICORIN
TPS

CROSS SECTIONAL VIEW OF

210 MW STEAM TURBINE

EXISTING DESIGN:
HP Turbine:
HP ROTOR : WITH MOVING BLADES OF T2 PROFILE
INNER CASING: WITH STATIONARY
T2 PROFILE

BLADES OF

INLET INSERTS: WITH 580X9 MM BUTTRESS

THREADS

EXHAUST ELBOWS: WITH SERRATED GASKET.

210 MW STEAM TURBINE

(REACTION DESIGN SET-KWU)

HP TURBINE
RETROFITTING 210
MW
REACTION
TURBINE
WITH
IMPROVED BLADING

HP INLET INSERTS
HP OUTER CASING
BREECH NUT

IMPROVEMENTS IN PROPOSED
DESIGN:
HP MODULE:
INNER CASING & HP ROTOR WITH
OPTIMISED HIGHLY EFFICIENT T4
PROFILE BLADING.
ADVANTAGE:
INCREASED EFFICIENCY

IMPROVEMENTS IN PROPOSED
DESIGN: (CONTD.)
HP MODULE (CONTD.):
MODIFIED HPT INLET INSERTS WITH
BUTTRESS THREADS OF SIZE 580X20
MM IN HP OUTER CASING & BREECH
NUTS.
ADVANTAGE:
EASE IN ASSEMBLY & DISMANTLING.

IMPROVEMENTS IN PROPOSED
DESIGN: (CONTD.)
HP MODULE (CONTD.):
MODIFIED HP EXHAUST ELBOWS
WHICH HAVE U-RING IN PLACE OF
SERRATED GASKET.
ADVANTAGE:
ENHANCED RELIABILITY.

HP EXHAUST ELBOWS
HP OUTER CASING

Exhaust Elb

HP EXHAUST ELBOWS

HP EXHAUST ELBOWS
U-RING

SCOPE OF SUPPLY
FOR HP TURBINE:
COMPLETELY
ASSEMBLED
HP
MODULE WITH T4 PROFILE BLADING
ALONGWITH MODIFIED HP INLET
ASSEMBLY & HP EXHAUST ELBOWS.

210 MW STEAM TURBINE

(REACTION DESIGN SET-KWU)

IP TURBINE
RETROFITTING 210 MW
REACTION TURBINE
WITH IMPROVED T4
PROFILE BLADING
ADVANTAGE:
IMPROVED PERFORMANCE.

SCOPE OF SUPPLY (CONTD.)

FOR IP TURBINE:
IP INNER CASING & IP ROTOR WITH
T4 PROFILE BLADING.
A SET OF HPR-IPR & IPR-LPR
COUPLING BOLTS.
NECESSARY KEYS ETC.

WORK REQUIRED TO BE DONE AT SITE:

[NOT INCLUDED IN THE SCOPE OF THIS
TECHNICAL OFFER]

PERFORMANCE TESTING PRIOR & AFTER

R & M.
OVERHAULING.
RLA STUDY.
COMPONENTS IDENTIFIED DURING
OVERHAULING/ RLA STUDY WHICH NEED
REPLACEMENT

WORK REQUIRED TO BE DONE AT

SITE: (FOR HP Turbine)
REMOVAL OF OLD HP MODULE FROM ITS
POSITION AFTER DISMANTLING OF HP INLET
INSERTS AND HP EXHAUST ELBOWS.
OLD HP INLET ASSEMBLY (INLET INSERTS
WITH BREECH NUTS) & HP EXHAUST
ELBOWS ARE TO BE CUT FROM MS PIPES &
CRH PIPES RESPECTIVELY.

WORK REQUIRED TO BE DONE AT

SITE:(CONTD.)
INSTALLATION OF NEW IMPROVISED
HPT MODULE IN POSITION, CENTERING
& ALIGNMENT.
WELDING OF HP INLET ASSEMBLY OF
NEW MODULE WITH MAIN STEAM PIPES.

WORK REQUIRED TO BE DONE AT

SITE:(CONTD.)
HP EXHAUST ELBOWS ARE TO BE
WELDED WITH CRH STEAM PIPES.
ASSEMBLY OF HP INLET INSERTS &
HP EXHAUST ELBOWS
TO BE
COMPLETED.

WORK REQUIRED TO BE DONE AT

SITE:FOR IP Turbine
REMOVAL OF OLD IP ROTOR & IP
INNER CASING.
INSTALLATION OF NEW IP INNER
CASING & IP ROTOR WITH T4
PROFILE BLADING, ITS CENTERING
& ALIGNMENT.
COMPLETION OF BOX UP OF IP
Turbine.

CONDITION AFTER R & M OF HPT & IPT

(UNDER RATED CONDITION):
RATED PARAMETERS:
At 100% MCR condition

MAIN STEAM FLOW : 641.3 T/HR

MS/ HRH STEAM TEMP:535/535 DEG C
MAIN STEAM PR: 150 ATA
BACK PR: 0.121 ATA

EXPECTED PRESENT PERFORMANCE:

CONSIDERING DETERIORATION DUE TO
AGING AS PER ASME-PTC-6 REPORT 1985
FOR AVERAGE LIFE OF 20 YEARS,
FOLLOWING WILL BE
EXPECTED
PERFORMANCE AT 641.3 T/HR MAIN
STEAM FLOW AND RATED PARAMETERS

OUTPUT: 202.3 MW
HEAT RATE: 2067 KCAL/KWH

COMPARISON OF PERFORMANCE:

PAY BACK PERIOD

1) REDUCTION IN OH PERIOD: 25 DAYS
RESULTING TO

ADDITIONAL POWER GENERATION FOR 25 DAYS

YIELDING TO

GUAREENTED MINIMUM ADDITIONAL REVENUE:

= 209MW x 1000 x 25DAYS x 24HRS x 0.80PLF x 2.00RS

=RS 20.06 CRORES

PAY BACK PERIOD

2) ADDITIONAL
ANNUAL
REVENUE
GENERATION DUE
TO INCREASE IN
OUTPUT & IMPROVED HEAT RATE:
= 6.7 MW x 1000 x 8000 HRS x 0.80 PLF x RS 2.00
= RS 8.576 CRORES PER YEAR
HENCE, PAY BACK PERIOD < 3 YEARS